Back Window Glass: Service and Repair

Replacing the rear windshield

Special tools:
951 2786 Handle 951 2786 Handle
951 2787 Knife blade 26 951 2787 Knife Blade 26
951 2788 Knife blade 38 mm 951 2788 Knife Blade 38 mm
998 6030 998 6030

Removing the rear windshield

Remove:
- the rear seat. See Rear seats Rear Seats
- the parcel shelf. See Parcel shelf Service and Repair
- the seat belts. See Rear seat belts Rear Seat Belts.
Remove the weatherstrip at the front edge of the tailgate opening.





Hint: Tape around the window to protect the paint.




Carefully cut off the rubber edge on the roof and D-posts as illustrated.




Cut out the windshield. Use special tool 951 2786 Handle 951 2786 Handle.

At the D-posts:
Start in the upper corner. Cut down along the D-pillar. Cut carefully around both corners. Use the long blade, special tool 951 2788 Knife blade 38 mm 951 2788 Knife Blade 38 mm.





Hint: Insert a plastic wedge (1) or similar between the windshield and the body flange to facilitate the cutting.

At the roof:
Start in the center and cut outwards. Use the long blade, special tool 951 2788 Knife blade 38 mm 951 2788 Knife Blade 38 mm.
Do the same from the other side. Take care at the corners.





At the bottom edge:
Open the tailgate.
Start from the center and work outwards towards the rear fender. Use the long blade, special tool 951 2788 Knife blade 38 mm 951 2788 Knife Blade 38 mm.
Do the same on the other side. Take care at the corners.




When the windshield is cut out, carefully lift the sides and disconnect the connectors for the heated rear windshield.




Apply the suction pads, special tool 998 6030 998 6030 , to the windshield. Lift the windshield out.

Installing the rear windshield




When working with PUR on the body flange, see PUR on body flange .
Clean the area on the window to which PUR adhesive is to be applied. Use cleaner-H (black cap).




Apply glass activator (yellow cap) to the area on the window to which PUR adhesive will be applied.




Apply glass primer (green cap) to the area on the window to which PUR adhesive will be applied. Apply generously (although not so much that it runs).
Let the primer dry until the surface is matte.
Apply the PUR adhesive activator (blue cap) to the remaining PUR bead on the body flange.




Load the PUR gun. Use the white nozzle.
Apply adhesive to either the window or to the body flange. Ensure that no PUR adhesive gets onto the terminals for the heated rear windshield.
Position the windshield. Place a few strips of masking tape on the windshield and part way over the roof to prevent the pane from sliding down during the curing process.
Connect the connectors for the heated rear windshield.

Install:
- the seat belts. See Rear seat belts Rear Seat Belts
- the parcel shelf. See Parcel shelf Service and Repair
- the rear seat. See Rear seats Rear Seats.